Wire and separation prep-tool

ABSTRACT

A wire and separation prep-tool comprising of a hand-held prolate cylindrical rod shaft base member with one dull radial pointed conically narrowed end for penetrating the space between twisted pair wires, with no harm or injury to said wires, then physically expanding the distance between the wires as the tool is further pushed and penetrates further as the main shaft&#39;s conical walls increase in diameter; then moving adjacent in the direction of the opposite end: a single diametrically cut circular groove cut in and around the base shaft deep enough to hold, align and to separate said twisted pair wires into two single wires with an operator&#39;s hand pull. Finally, with multiple strokes per wire in this same groove, the tool can completely straighten a single wire from its pre-form wound; then continuing adjacent, a wider singular diametrical cut circular groove cut in and around the main base shaft to rub multiple times against a sheathed group of twisted wire pairs and smooth out inside kinks from the outside near the end to be terminated; then continuing adjacent, a designated length of an insulated tubular hand grip formed around the mid-section of the cylindrical rod for a 360 degree tubular grip; then continuing adjacent, a series of five diametrically cut circular grooves cut in and around the mains base shaft so to allow the field operator to correctly hold and pre-align five singular wires for the ease of plural wires installation into a female RJ-45 jack receptacle; then continuing adjacent, located at the center of the flat perpendicular end of the second end of the cylindrical rod shaft base is a centered rectangular notch thru the longitudal and horizontal axis which allows a sideways entry, perpendicular insertion of plural wires into the notch for narrowing, flattening, and pre-aligning into the prescribed positions for ease of these plural wires installation into a male RJ-45 plug. In summary, and as described herein, this compact tool invention has a total of five (5) distinct and integral subparts identified within to perform six different tasks on Category 1-10 twisted wire pair cables.

REFERENCES CITED: [REFERENCED BY]

3906561 September, 1975 Bawa  7/5 4025998 May 1977 Eppler  29/5664444228 April, 1984 Demirjian 140/23 4620573 November, 1986 Meder.140/123 4713874 December 1987 Shwartz  29/566 4797988 January, 1987Bowden Jr.  29/566.4 5771945 June, 1998 Jenner, et al. 140/123 6584670July, 2003 Costa  29/564.7 6601615 August, 2003 Hammond 140/23 6604268August, 2003 Fujita, et al.  29/33F

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

“Not Applicable”

STATEMENT TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTINGCOMPACT DISC APPENDIX

“Not Applicable”

DESCRIPTION

1. Technical Field

The present invention relates to a twisted wire preparation tool andmore particularly to a hand held, inexpensive, compact, prolate,lightweight, multiple-tasks performer, labor-saving, and simple-to-usetool which enables the tool-operator's maneuverability, and ability toproperly separate, straighten and align single and plural wires for twodifferent types of RJ-45 connectors, female plugs and male jacks,without inflicting harm to the jacket sheath, wire or wire insulation.

2. Background of the Invention

In the telecommunications, electronics and computer industries, shielded(STP) and unshielded twisted pair (UTP) wires have been the fasterperformance replacement wire for coaxial cable, not only used fornetworking but also for the traditional telephone. There are 10different types of STP/UTP categories and, depending on what you want toachieve, you would need the appropriate type of cable. Yet allsheathed/unsheathed jacket cables and their twisted pair wires in thesecategories can be separated, straightened and aligned with this new toolinvention. Here are UTP Categories 1-6 that serve most applicationsworldwide at this time.

The Different UTP/STP Twisted Pair Wire Categories

-   Cat. 1 Data rate up to 1 Mbps Traditional telephone ISDN (one wire)-   Cat. 2 Data rate up to 4 Mbps Token Ring-   Cat. 3 Data rate up to 10 Mbps Token Ring and 10 BASE-T-   Cat. 4 Data rate up to 16 Mbps Token Ring-   Cat. 5 Data rate up to 100 Mbps Ethernet-   Cat. 6 Data rate up to 16 MMbps Fast Ethernet and Token Ring-   Cat. 5e Data rate up to 1000 Mbps Gigabit Ethernet-   Cat. 6 Data rate up to 1000 Mbps Gigabit Ethernet-   Cat. 7-10 Data rate up to 10,000 Mbps Shielded Twisted Pairs in    Research and Military

The number identified in each category (example: Cat. 2), where thenumber two refers to the number of twists per inch inside the wiresheath (and the quality of a connection in a jack). The “twist” effectof each pair in the cables will cause any interference presented/pickedup on one cable to be cancelled out by the cable's partner which twistaround the initial cable. Please note that Cat. 1 is only a single wire,yet may be serviced by this tool also.

In general, the number of twisted wires, wire length, wire type, andphysical separators also dictate the performance of twisted wire pairs.Cat. 2, Cat. 3, Cat. 4 Cat. 5 and Cat. 6 are network wirespecifications. Cat. 5 and Cat. 6 have become today's standards and mostwidely used with four twisted wire pairs per sheathed cable due to thegrowth and continued demand for faster data transmission speeds forprivate, public and governmental entities.

Lastly, STP/UTP wire cables are terminated with standard connectors,jacks, plugs and punchdowns. The standard jack/plug is often referred toas a RJ-45, but that is really a telco designation for the “modular 8-10pin connector” terminated with a UPOC pinout used for telephones. Themale plug on the end of a patchcord is called a “plug” and the femalereceptacle on the wall outlet is a “jack”. These may connect into thehub or computer's network card.

This Wire And Separation Prep-Tool invention prepares twisted wire pairsin two general ways with convenient 5 subparts, so to be inserted intoeither a plug or jack. In addition, this hand tool invention reduces theharm and damage inflicted when compared to wires that are frequentlyseparated with a knife, screwdriver or other nonconforming items. Nicks,cuts and other damage causes significant amount of undesirable RadioFrequency (RF) transmissions. Plus, this combination tool reduces thetime and effort to straighten and untwist the twisted pair wires whencompared to “hand & fingers” which is still the predominant standard inthe industries, and since it has 5 specific subpart tool instruments perthis one tool invention, it reduces the amount of tools required by theoperator and the amounts thereby expensed.

Therefore, it will be appreciated that there is a big need for amulti-task tool which enhances the practicability of terminatingCategories 1-10, RJ-45 connectors, by properly separating,straightening, and aligning any twisted wire pair so to match the plugor jack requirements quickly and economically.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide animproved twisted wire preparation tool that has 5 multiple task subparttool functions to perform six distinct tasks.

It is a further object of the present invention to provide a twistedwire preparation tool which appreciably enhances termination of RJ-45connectors in STP/UTP Categories 1-10 in the field for new wire andreceptacle installation, repair, maintenance and/or new wireinstallation on a new product at it's manufacturing plant.

It is a still further object of the present invention to provide acompact, lightweight, inexpensive, and multi-task time reducing twistedwire preparation tool that penetrates and separates twisted wire pairssafely, quickly straightens single wire, aligns single and plural wirescorrectly for proper insertion into RJ-45 jacks, and narrows andflattens single and plural wires for proper insertion into RJ-45 plugs.

It is a still further object of the present invention to provide aunique twisted wire multi-preparation tool which has multiple taskfunctions that minimizes the time for labor & organization whileminimizing overall tool expense.

In general, this is a solid prolate cylindrical shaped rod shaft thathas two ends; the first end being a conically narrowed round dullpointer for safely penetrating twisted wire pairs; adjacent is theoverall expanding conical shape shaft which assists with it's inherentexpanding diameter wall slope to increase the distance of separationspace between the two twisted wires, as they are continually penetratedwith the tool, until the two wires are caught by and semi-held intoopposing groove channels at the top by the first diametrical cutcircular groove. Thus by the operator pushing the tool's pointed tipabout an inch forward in between the wires until they rest in the firstdiametrical cut circular groove, this allows the wires preformedcompression to assist in adhering to the tool's first concentricgroove's walls just long enough to allow the operator, by hand, to pullup horizontal and leverage the longitudal rod shaft base tool toforcefully continue separating several inches (1-7 inches) in length ofthe twisted pair wire's ends entirely apart into two single wireswithout harm.

Then the operator replaces one of the same wires back into the grooveand applies thumb holding pressure to the wire and uses the same singlediametrical cut circular groove to continuously rub the wire into . . .stroke the single wire up and down and allow this repetitive motion inthis groove helps re-mold and straighten the wire with this procedure.Once each wire has been straightened in such a manner, then the wiresare ready for the next of one of two steps depending on which RJ-45connector is the require target.

For the RJ-45 “jack”, place the wires in proper order according to theschematics and insert the straightened five single wires, each one intoone of the five evenly-spaced diametrically cut circular grooves,traverse and horizontal to the tool's longer longitudal shaft, therebypre-aligning all 5 wires (10 wires total: two sets of five) into thespecifically spaced grooves matching the same wire pattern as thisproposed connector. Once the wires are ready, insert in the jack andlock down with a standard crimp tool.

For the RJ-45 “plug”, it's different. First, position the straightenedwires into the order prescribed by the schematics. Then, find therectangular notch centered into the longitudal and horizontal axis atthe flat end of the second end to push the connecting wires' endssideways into this notch. This notch will narrow and pre-align thesewires into a specific sized pattern exactly like that of the targetRJ-45 plug. If needed, trim the wires for either the RJ-45 plug or jackwire placement prior to actual wire insertion in either the notch orfive grooves, respectfully, for immediate final crimping of the wiresinto the plug or jack.

Located 360 degrees around the entire outside diameter of only themiddle section of the prolate cylindrical rod shaft is an insulatingtubular hand grip. It lies, by, and between the single wider sheathgroove on one side and the inner and closest of the 5 plural wirediametrically circular grooves on the other side. It enhances grip whileminimizing low-voltage shock of any live electrical wires.

This lightweight hand tool may fit in a top shirt pocket, pants pocket,briefcase or tool pouch just like a similar sized fountain pen. Thisgives it a compact status and is further significant because this onetool invention has 5 tool subparts that technically perform the job of 6tools as described here within.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 identifies the REFERENCES of all major subpart components andillustrates the Side View of the entire WIRE AND SEPARATION PREP-TOOL,including all particular subpart components in accordance with thepresent invention.

FIG. 2 is a Top View of the entire WIRE AND SEPARATION PREP-TOOL inaccordance with the present invention.

FIG. 3 is a First End View of the round tip, diametrical shaft, andconcentric hand grip.

FIG. 4 is a Second End View of the centered notch, diametrical shaft andconcentric hand grip.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 1, a prolate cylindrical rod shaft tool havingtwo opposing ends longitudal, one conically narrowed to a small dullpointed round mammilated end (see REF. 1), the other end perpendicularlyblunt yet notched (see REF. 7). Located in between the two opposing endsis a strategic series of diametrically cut circular grooves of variousdepths and widths along the longitudal base shaft for specific tasks andapplications (see REF. 3, 4, 6), along with an adhering concentricinsulating tubular hand grip located in the middle section (see REF. 5).

This tool is a hand tool. The tool's length is 5.1″ (″=inches) and has amaximum diameter of 0.25″ except less where strategically grooveddiametrically. Also with reference to FIG. 1, REF. 1, 2, 3, 4, 6, theprolate cylindrical rod shaft longitudal tool has five (5) subpartsdescribed below able to collectively perform six (6) distinct anddifferent tasks. SUBPART FIG./REF. TASK Subpart 1: FIG. 1, REF. 1: FirstEnd for Wire Separation and Conical Shaft Spreader Subpart 2: FIG. 1,REF. 3: Single Wire Grooves for Holding and Separating TWP (secondSubpart 2 task): Single Wire Groove for Holding and Straightening 1 wireSubpart 3: FIG. 1, REF. 4: Widest Groove for Smoothing Cable JacketSheath Subpart 4: FIG. 1, REF. 6: 5 Wire Grooves for pre-aligning wiresinto RJ-45 jack Subpart 5: FIG. 1, REF. 7: Second End Notch forpre-aligning 5 wires into RJ-45 plug

This hand tool is similar to the size, weight of 250 grams, and, even,the prolate shape of a solid fountain pen. It's convenient and compactsize allows it to be carried in a shirt or pant's pocket, tool pouch orbriefcase. A number of materials are suitable for the cylindrical rodshaft tool, as well as for the insulating tubular hand grip. The firstsubpart of this tool invention is a dull pointed mammilated end of 0.05″diameter and 0.1″ long for penetrating twisted wires as seen in FIGS.1-3, REF. 1. This point must be a rounded yet have a dull point so notto break, cut, scrape, inflict nor harm an individual wire's outerinsulated coating. The connecting shaft from the first end's point mustbe a narrowed shape of 0.04″ diameter and 0.07″ length to enter between,catch and hold the two twisted flexible wires. Once the space betweenthe twisted wires is penetrated, the next 0.355″ of overall conical baseshaft shape progressively assists in separating the wires with it'sinherent expanding diameter from 0.04″ to 0.23″, and 50 degreeincreasing slope as it leads away from the first end. As the wire ismanually pushed up the conical shape for about an inch, the increasingdiameter increases the distance of separation between said twisted twowires, until the two wires are automatically caught by, and semi-heldinto an adjacent position by the first diametrical cut circular groove(described more below as “second subpart”), where then the operator maypull on the tool outward and thereby separate up to seven inches of thetwo wires ends entirely. Now the wires are ready for straightening andtrimming, as required.

The second subpart of this tool invention is the first end's firstsingular diametrical cut circular groove around the rod shaft locatedproximal down shaft of the greatest diameter of the conical shape asseen in FIGS. 1-2, REF. 3, and 0.605″ from the first end. The singlegroove's walls are diametrically concentric, convex to the horizontalaxis, and planar back face which provides an excellent guide surfacewith which to hold and realign wire. The groove's floor is convex andassists in holding the wire. Upon penetrating, dividing, and wideningthe two wires of the twisted wire pair with the tool as described, theoperator can now begin to apply hand force to be able to pull or pushthe tool horizontally up the wire's longitudal axis in the samedirection as the wires twist pattern and separate this pair into twosingle wires. Again, at this time, a common commercial wire cuttingapparatus may be needed in the procedure to trim the length and/or theinsulated plastic coating, and/or the outer loose jacket sheath, ifneeded.

The third subpart referenced herein includes a wider singulardiametrically cut circular groove of 0.19″ diameter and 0.2″ length withobtuse walls of 140 degrees angled outward, as seen in FIGS. 1-2, REF.4. The groove's floor channel is concave. These wall and floor channelangles allow for safely rubbing this groove part of the tool back andforth on the plastic protecting jacket sheath on the ending 2 or 3inches that surrounds a group of twisted wire pairs. The result here isto smooth kinks and ridges protruding from the loose jacket sheath andto assist in aligning and preparing twisted wire pairs for the followingprocedures, outlined herein, and finally, for plural wire terminationinto a RJ-45 plug or jack. This diametrical groove is located in betweenand proximal 0.35″ from the aforementioned single narrower groove and0.24″ from the tubular grip adhered to the base tool shaft describedhere below.

The fourth subpart of this tool invention is the series of five evenlyand strategically spaced, diametrically cut circular grooves in andaround into the cylindrical shaft rod that assist to hold and pre-alignup to five wires to then be fitted directly into a R-45 jack. FIGS. 1-2,REF. 6 illustrates these five diametrical grooves that have anindividual length of 0.032″, a combined total length of 0.61″ from thefirst to the fifth, individual diameters of 0.16″, and are evenly spacedat 0.112″ apart. The grooves' walls are convex and 90 degreesperpendicular to the longitudal axis to assist in holding the wires inplace for alignment. The grooves floor is flat and deep enough to assistin holding the wires in place for alignment. Once the wires straightenedand pre-aligned, they are removed from the tool and placed into theRJ-45 jack receptacle and an acceptable industry punch-down tool is usedto push lock the pre-aligned wires into a permanent connection.

The fifth subpart of this tool invention is the centered rectangularnotch, 0.04″ height by 0.25″ width by 0.48″ length, located at and thruthe second end of the longitudal shaft rod as shown in FIGS. 1 and 4,REF. 7. The purpose of this centered longitudal rectangular notch is toallow easy placing, arrangement, narrowing, and pre-aligning of theseparated and straightened plural wires, of Category 1-10 twisted wirepairs, for insertion into a RJ-45 plug receptacle. Upon proper pluralwire arrangement and alignment and the actual wire insertion into aRJ-45 plug, an acceptable industry crimper is used to lock down thewires in their precise connector position.

As stated above, this hand tool also features an insulating concentrictubular hand grip made from plastic, rubber or other material thatsurrounds and tightly adheres to the outer cylindrical tool shaft in themiddle area so to not slip as seen in FIGS. 1-4, REF. 5. The grip'sdimensions are 2.3″ length and 0.005″ thick, 0.265″ outside diameter,and located 1.64″ from the end of the first end and 1.63″ from thesecond end. The hand grip gives the operator's hand a more securesurface to grasp and provides an insulated protecting material in casethe wire is live and low voltage shock is a potential threat. The colorof said grip may be produced black or any other color.

This hand tool contains five referenced subpart tool functions thatperform a total of six tasks. This hand tool is a weight-savingalternative to carrying and operating six tools; a cost savingalternative—inexpensive option to purchasing six different tools; and, atime saving alternative that will reduce the organization and actuallabor time of handling six different tools for the same job.

Alternatively, this hand tool's length may be manufactured severalinches shorter or longer. This hand tool's diameter may be manufacturedlarger or smaller. This hand tool's singular and plural grooves may bemanufactured deeper or shallower or increased in quantity shouldIndustry Standards dictate so for more wires in a receptacle. This handtool's concentric tubular hand grip may be manufactured in variouslengths, colors, and from various materials, including, but not limitedto, plastic, rubber or synthetic materials. This hand tool's cylindricalbase shaft may be manufactured from many types of materials, including,but not limited to, plastic, carbon fiber, metal, alloys, wood, rubber,or any mix hereof, and in various colors or finishes. Thus, this handtool's weight may change due to the compositions and/or mixes madethereof.

1. A hand tool for separating twisted wire pairs, said tool comprising aprolate cylindrical rod shaft base having a first end and a secondopposing end and a longitudal axis extending between the first end andthe second end;
 2. A tool as in claim 1 wherein the prolate shape ofsaid hand tool increases the design appeal and marketability;
 3. A toolas in claim 2 wherein said tool comprising a prolate cylindrical rodshaft base has an outside diameter of 0.25″ except at the first end andall other diametrical locations along the longitudal axis wherediametrical cut circular grooves are located along the rod shaftindicated herein and where the insulating concentric hand grip slightlyexpands the main tool shaft's diameter;
 4. A tool as in claim 3 whereinthe first end having a narrowing mammilated pointed round end, thennarrowing in diameter, and then progressively expanding conically indiameter at an acute angle of 50 degrees until reaching the maximum baseshaft diameter. The first end point is protrusively centeredlongitudally, so to easily penetrate the air space between flexibletwisted wire pairs, yet dull, and radially blunt enough, not to inflictcuts nor scraping on the insulated wires while forcefully separatingthem as the wires slide onto and up the conical rod shaft by humanforce;
 5. A tool as in claim 4 wherein a single diametrical cut circulargroove is located approximately 0.605″ from the first end and it'sconcentric sidewalls, perpendicular to the longitudal axis, allowtwisted wire pairs to be held oppositely while separating them entirelyapart as the operator pulls the tool up horizontally to the tool'slongitudal axis;
 6. A tool as in claim 5 wherein the same singlediametrical cut circular groove identified in claim 6 above will alsobend and straighten an individual wire with repeat rubbing and strokingof the groove's walls against the wire until smooth and straight;
 7. Atool as in claim 6 wherein a second proximal single diametrical cutcircular groove is located for rubbing and smoothing a cable jacketsheath along. The groove is located by and between the first end's firstsingular diametrical cut circular groove, as described in claims 5 and6, and the rubber/plastic cylindrical tubular grip, described in claim10. This groove accepts, aligns and smoothes the cable's jacket sheathby manual rubbing force on the Category 1-10 twisted wire pairs in theiroriginal plastic protector jacket sheaths. Continued rubbing smoothesout obvious lumps and ridges, which allows pre-preparation of the cableend prior to separating the twisted wire pairs;
 8. A tool as in claim 7wherein the second end of the cylindrical rod shaft base is a horizontalflat circular end perpendicular to the longitudal axis;
 9. A tool as inclaim 8 wherein a series of five evenly-spaced diametrical cut circulargrooves are near the second end to pre-aligning plural wires for aconnection into a RJ-45 jack receptacle. All five grooves' walls areconvexly perpendicular to the base tool's longitudal axis to assist inholding said wires in the each channel. The five diametrical cutcircular grooves are located between and proximal to the flat circularperpendicular second end and the plastic/rubber concentric insulatinghand grip described in claim 10;
 10. A tool as in claim 9 wherein ainsulating cylindrical tube hand grip adheres diametrically along andaround the outside middle area of the base rod shaft, lying in betweenthe first end's wide single sheath groove and the first of theevenly-spaced plural diametrical cut circular grooves towards the secondend;
 11. A tool as in claim 10 wherein a rectangular notch is positionedprecisely thru the center longitudal and horizontal axis of the flatperpendicular circular end of the second end, extending from and thruthe shaft end and extending back in length towards the direction of thefirst end. This notch provides narrowing and pre-alignment of pluralwires for a RJ-45 plug connection receptacle;
 12. A tool as in claim 11wherein this one multi-hand tool invention contains five referenced toolsubparts, each with a distinct and different performance task ofpreparing Shielded and Unshielded Twisted Pair wires in specific waysdescribed herein for RJ-45 plug and jack receptacle connections, and,all together, eliminating literally nonexistent and potentiallyexpensive multiple tool purchases, thus saving preparation andorganizing time and the number of tools and weight carried by anoperator;
 13. A tool as in claim 12 wherein this one hand tool inventionis an inexpensive time-saving alternative to purchasing and using sixseparate tools, and, especially cost and time saving when compared tothe time savings in labor costs where untwisting wires and straighteningwires by actual hand is still the predominant technique of theIndustries;
 14. A tool as in claim 13 wherein is a lightweight,convenient to use, compact, stiff tensile strength to penetrate, pullon, leverage and separating up to seven inches of twisted wire pairsinto singles without breaking the wires or the tool;
 15. A tool as inclaim 14 wherein a method for separating twisted wire pairs isestablished;
 16. A tool as in claim 15 wherein a method forstraightening a single wire is established;
 17. A tool as in claim 16wherein a method for pre-aligning one set of five wires for duplicateplacement into a female RJ-45 jack connector receptacle is established;18. A tool as in claim 17 wherein a method for narrowing andpre-aligning one set of five wires for duplicate placement into a maleRJ-45 plug connector receptacle is established;
 19. A tool as in claim18 wherein the quantity of 1-5 wires pre-aligned may vary depending onthe actual wire connection needs of the operator, but allows five here;20. A tool as in claim 19 wherein the prolate slender and compact shapeincreases the design appeal and the operator's convenience in carryingability in a top shirt pocket, pants pocket, as well as in a tool pouch,tool box or briefcase.